Method of making toys and the like and step product



H. PALAIS Jan. 5, 1932.

METHOD OF MAKING TOYS AND THE LIKE AND STEP PRODUCT Filed A ril 9, 1930 2 Sheets-Sheet 1 Jan. 5, 1932. H. PALAIS 1,839,889

METHOD OF MAKING TOYS AND THE LIKE AND STEP PRODUCT Filed April 9, 1930 2 Sheets-Sheet 2 Patented Jan. 5, 1932 u 1 rs HARRY PALAIS,:OF BOSTON, MASSACHUSETTS METHOD OF MAKING TOYS AND THE LIKE AND STEP PRODUCT Application filed April 9, 1930. Serial No. 442,989..

. This invention relates to the manufacture of articles such as toys and the like formed largely of sheet material such as cardboard or fiber. One object of this invention is to provide a method of manufacture'by which the advantage of cutting by the use of steel rule dies or the like, which are suitable for cutting relatively thin material only, may be secured and yet by which cut figure elements of any desired thickness may be produced.

A further object is to provide a method by which operations subsequent to the cutting may be accomplished with accuracy and great facility and with a relatively small amount of handling.

Further objects and advantages will appear from a more complete description of certain embodiments of this invention shown in the accompanying drawings in which Figure 1 is a perspective view of a single sheet of cardboard or the like after certain figure elements have been cut therein.

Figure 2 is a perspective illustratingthe building up of the elements of the desired thickness by securing together a plurality of sheets such as is shown in Figure 1.

Figure 3 is a perspective illustrating the next step in the process, all the waste between the figure elements with. the exception of a gate having been removed.

Figure 4 is a detail section showing the manner in which a plurality of assemblies similar to that shown in Figure 3 are dipped for application of a ground color or other coating thereto.

Figure 5 is a diagrammatic perspective showing the manner of securing proper positioning of the figure elements for color printmg.

Figure 6 is a fragmentary perspective showing one of the figure elements still attached to the gate and provided with an axle and wheels.

Figure 7 is a section on line 77 of F igure 6.

Figure 8 is a view similar to-a portion of Figure 7, but showing the figure elements detached from the gate.

Figures 9 and 10 are views somewhat similar to Figure 3, but showing elements for other portions of the same toy.

Figure 11 is a perspective showing a set of parts in disassembled relation taken from the articles such as are illustrated in Figures 9 and 10.

ing

wheels arranged toy.

assembly of a different Figure 1.4 is a rear elevation of the same. Figure 15 shows in perspective a gated toy nearing completion.

toy shown in a Figure 16 is a perspective of a'completed portion of Figure 15 in uncompleted form.

In accordance with this invention a plulity of sheets of relatively thin material ch as cardboard, such as shown at 1 in Figure 1, have cut therein a plurality of figure elements,

such as 2, which may, if desired, and as shown be joined together by gate portions such as 3 from which the figure elements are partially severed as by lines of peripheral portions of Where the several sheets elements are out are not ateiy to size, provision rforations as at 4 along relatively short the figure elements. in which these figure previously cut accurshould also be made orm guiding surfaces by which the several sheets may be placed in superposed relation with the figures and gates in registry.

As shown in Figure 1 such portions are shown Ehedfigures and gates in the sheet may cut in the sheet as at 5. This cutting of well one by means of the well known steel rule dies, since by the use of such dies comparatively intricate patterns and figure outlines may be formed with great facility. However, such dies are not well adapted for cutting material of considerable thickness.

The figure portions with their gates are not separated or removed from waste portions of the sheet immediately after being cut, but several sheets thus cut with the same figure elements and arranged identically are then assembled in face to face relation as shown 1n Figure 2 and secured together in any suitable way as by adhesive applied to their confronting faces. In Figure 2 it will be seen that these several sheets are assembled on a fixture or jig which as shown comprises a board or platform 10 having guide members 11 extending thereform which are shaped to engage the registration cuts 5 of the sheets so as to insure that the sheets when assembled have their figure portions and gates in registry. The sheets thus assembled are preferably subjected to sufiicient pressure to insure proper adhesion and the adhesive is permitted to harden.

After this has been efiected waste portions of the material between the figure elements,

with the exception of the gates, are removed, this leaving, as shown in Figure 3, a plurality of laminated figure elements 15 secured together in the original positions in which the figure elements were cut in the several sheets by laminated gate portions 16 from which these figure elements are partially severed as by means of the perforations made in the original cutting operations. By permitting the cut figures to remain unseparated and the waste material to remain in position until after the figure elements have been built up to the desired thickness and dried they are held sufiiciently rigidly in their initially cut positions so as to insure proper registry of the elements in the several sheets, to prevent warping or distortion in handling and during drying or setting of the adhesive, and to produce in the step. product, such as shown in Figure 3, a sufficiently rigid structure to permit further handling and manufacturing operations to be performed thereon without danger of displacing the figure elements from their original relative positions. All the assemblies of the same figure elements are thus identical and properly cooperate with jigs and fixtures designed to receive them during subsequent operations. The gate portions also furnish parts which may be grasped or otherwise engaged during the various operations and thus avoid any injury to the figure elements which might be caused by direct engagement of handling devices therewith. This attachment of the several spaced figure elements together by the gates permits the several figure elements to be treated as units during subsequent manufacturing operations after which they may be detached from the gates.

The particular manufacturing operations carried out While the plurality of elements are connected as by the gates depends much on the character of the articles to be made therefrom. It will usually'be found desirable, however, to first coat the side faces and exposed edges of the elements with coloring material which forms a ground color, that is, an initial coating color, preparatory to applying other colors on certain portions as by a color printing press. As shown in Figure 1 this initial coating with the ground color may be effected readily by securing the assembled figure elements and gates in spaced relation to a suitable supporting board 20 as by means of projecting points or pins 21 upon which the gate portions of the assemblies may be impaled in spaced relation. This board may then be inverted and the several' assemblies of figure elements and ates immersed in a suitable tank 22 contalnin the coating or coloring material as at 23. cans of any suitable type may be provided, as the spring clamping jaws 24 shown in Figure 4, for engaging the board 20 so as to permit the assemblies to be withdrawn from the coating material when desired, whereupon they are set aside to dry. After drying the assemblies may be removed from the board 20 while the elements are still attached to the gates and they may then -be color printed. In Figure 5 is shown diagrammatically the manner in which this may be accomplished, there being provided jigs or forms 25 having suitable positioning elements 26 thereon so spaced as to engage the several assemblies in such position that as the members 25 are passed through the printing press the printing rolls, one of which is indicated diagrammatically at 27, apply the colors to the desired portions and to those portions only of each figure element. It will be understood, of course, that it is usual practice in color printing to provide means for insuring the proper registration of sheet material placed accurately on jigs which are fed through the machine in predetermined relation to the printing areas on the several color printing rolls. By the use of the gates which support the several figure elements in exact predetermined relation the placing of the elements in proper relation for the desired registry of the color printing areas is easily insured, the several elements attached together by the gate portions being treated as a single unit for this operation.

After the printing operation various other I they were detached from the gates. For example, the assembly of elements may be supported on suitable forms and wheels and axles be applied thereto as shown, for example in Figures 6 and 7. Referring to these gures, the wheels are shown at and the axle at 31. These wheels may be preformed wooden wheels if desired, which may be bought commercially with the. axle 31 assembled in one and a perforation to receive the axle in the other. The holes for the passage of the axle may be drilled after the figure elements have been built up, but they are preferably cut in the original sheets of material as circular cuts as at 28 so that they are accurately positioned to receive the axles, the axles each with one wheel attached being inserted through one face of the assembly at the desired points. The other wheel is placed in position on the opposite end of each axle and is struck with a hammer to thus fix the wheel in position.

If desired the waste within the circular cuts which form the axle openings may be left in substantially its original position and if desired until at least after the dipping operation since this prevents the openings from becoming more or less stopped up by the coloring material. This waste may be left in position until the axles are inserted, the axles serving as ejecting plungers therefor. The holes are thus free and clear of obstructions and are accurately square with the faces of the figure element so that the wheels may always run true and free without any attention being given to this end during manufacture. When the wheels have been attached, the individual figure elements may be detached from the gate along the line of perforations as is shown at 32 in Figure 8.

In Figures 9 and 10 are shown assemblies of other figure elements which have been made by initially cutting the elements in individual sheets, fixing the sheets together with the elements in superposed relation and then removing the waste with the exception of the gates, as has been described in connection with Figures 1, 2 and 3. In Figure 9 there is shown one main gate portion to which are connected rear wall portions 41 for a cart, and tongue and base portions 42 for the same cart. Connected to parts 43 of the elements 42 are front wall cart portions 44. In Figure 10 a main gate portion 45 is shown to which are attached the side cart portions 46. These assemblies of elements are preferably coated and color printed as has been heretofore described in connection with Figures 1 to 5, whereupon these elements are detached from the gate and may be assembled to form the cart, the relationship of these elements for assembly being indicated at Figure 11. The end wall members 44 and 41 are shown as provided with laterally extending l. shaped tabs which may be fitted within slots of the. side wall members 46 and these side wall members are also shown as provided with slots 51 in which may be engaged lateral projections 43 and 52 on the combined bottom and tongue member 42 by which construction the cart may be assembled without .the use of nails or other fastening means. This method of forming and interlocking the cart wall members, however, is not claimed in the present application but forms certain of the subject matter of another application filed November 11, 1930, Serial No. 494,884 for sheet material article and method of making the same. The cart having thus been assembled, wheels and axles may be secured thereto. The wheels may be formed from sheet material cut and adhesively secured in superposed relation to the desired thickness as has heretofore been described, Figure 12 showing the manner in which the wheel elements may be associated with gates 61 for operations such as coating and coloring and such others as may be desired. While the wheels 60 are attached to the gates they may'have secured centrally thereto wooden disks 62, which are. better adapted to receive the ends of the axle 63 (see Figure 14) than is the material of which the wheels 60 are made. The disks 62 may be fixed to the wheels 60 in any suitable manner as by small metal fastenings 64, or by ad hesive as may be found the most suitable. By the use of suitable jigs (not shown) cooperating with the gated wheel assembly, the disks may be fixed accurately centered with great rapidity. Ater the disks 62 have been fixed to the Wheels 60 the wheels may be detached from the gates 61.

In place of the wooden disks 62 openings somewhat larger than the axles may be cut in the individual wheel elements 60, and the waste removed after the individual sheets are assembled and before the dipping operation. Within each of these openings 70 is then inserted a tubular plug -71 (Fig. 120) having its internal bore of a size and shape suitable to receive the axle. The wheel is then dipped. .This method can also be employed for mounting the axles in the body portion of the toys if desired, in which case the tubular plugs would usually have their openings sufliciently large to permit rotation of the axles therein.

The toy rabbit figure shown in Figure 6 may then be assembled with the cart, this figure as shown being provided with a notch 65 which may be engaged over the rear edge portion 66 of a slot 67 in the combined tongue and base portion 42 of the cart, and this figure may also be provided with a ledge portion 68 which may be brought into engagement with the under face of the member 42, as shown in Figure 13. This assembly completes the formation of this particular toy, or if desired for greater security, a single nail 69 may be driven through from one side of themember 42 into engagement with the rabbit figure.

As illustrating a somewhat different line of operations which may be performed on the step products comprising the several figures attached together, if desired, by the gate portions, reference may be had to Figures 15 and 16 in which the several figure elements 70 and 71 are shown as attached together in predetermined arrangement by gate portions 72. While they are thusheld they may be attached to opposite faces of the small boxes 73 and through perforated projecting portions of the several figure elements may be placed axles 74 on opposite ends of which are fixed wheels 75. Certain of these wheels and axles are shown in position in Figure 15. After this assembly is completed the individual wheeled boxes are'then detached from the gate members to form the completed wheeled box toys such as are shown in Figure 16. In any case where interference between the wheels of adjacent boxes would occur'before detachment, one axle with its wheels for one box may be placed in position before the boxes are broken apart after which the other axle with its wheels may be assembled in position. In general the gated portions of the several elements should be so situated as to be more or less covered by other portions of the toy or other object when completed. For example, as shown in. Figure 15, the gated portions for the elements 70 and 71 are covered over by the wheels 7 5 so that they do not show in the finished product. Similarly the gate ortions for the figure element shown in igure 6 are attached at two points, one of which comes beneath the wheel 30, and the other ofwhich comes at the sole of the foot 76 of this figure where it is wholly unobjectionable and indeed may be ornamental, representing a roughened shoe tread. Of course wherever it may be desired the edges left where the gate was attached may be given additional finishing operations, being smoothed or coated or colored as desired, though in most cases it is found quite unnecessary to do anything of this kind particularly where the gating is properly chosen with reference to the outline of the figure element. For the more expensive constructions, or where for any reason refinishing of gate edges would be objectionable or where gates are not necessary to hold the articles assembled the articles may be out completely without gates, and after the several sheets are fixed together any waste may be removed and the articles carried through subsequent operations and individually if desired.

It will, of course, be evident from this description that many different manufacturing operations may be performed to advantage while the figure elements are still attached to their gate portions, depending on the particular articles to be made, those described herein having been chosen merely by way of example and to illustrate certain of the advantages of handling a lurality of figure elements as a single unit or such operations. It will also be apparent that many other changes and modifications might be made therein without departing from the spirit or scope of this invention as defined by the appended claims.

I claim:

1. .The method which comprises cutting similar figure elements in a plurality of sheets of material, securing the sheets together in face to face relation, and-then removing the waste material about the margins of said elements. Y

2. The method which comprises cutting similar figure elements in a plurality of sheets of material, adhesively securing the sheets together in face to face relation, and then removing the waste material about the margins of said elements.

3. In the method of making laminated cutouts, the steps which comprise cutting similar figure elements in a plurality of sheets of material, securing the sheets together in face to face relation with the figure elements of the several sheets in registry, and separating the laminated figure elements thus formed.

4. In the method of making laminated fig-' ure elements, the steps which comprise cutting similar figure elements in a plurality of sheets of material, securing the sheets together in face to face relation with the figure elements of the several sheets in registry, and printing on the face of the laminated struc- 'ture so formed in predetermined relation to 6. The method which comprises cutting similar figure elements in a plurality of sheets of material, securing said sheets together face to face with said figure elements in registry, removing the waste material between said elements from the assembled sheets with the exception of gate portions which maintain the figure elements in the relative arrangements in which they were cut in the several sheets, and performing subsequent operations while they remain secured to said gate portions.

7. The method which comprises cutting similar figure elements in a plurality of sheets of material, securing said sheets together face to face with said figure elements in registry,

removing the waste material between said elements from the assembled sheets with the exception of gate portions which maintain the figure elements in the relative arrangements in which they were cut in the several sheets, and dipping said elements while so held together by said gatesin coating material to coat the side faces and exposed edge portions of said elements, and performing subsequent operations while they remain secured to said gate portions.

8. The method which comprises cutting figure elements in the same relationship in a plurality of pieces of sheet material, adhesively securing said sheets together in face to face relation with the edges of the corresponding figure elements in the several sheets in registry, permitting the adhesive to dry, removing the waste portions from between said figure elements with the exception of gate portions joining the several elements to maintain them in the relative positions in which they were cut in the individual sheets, color printing said elements while attached to said gates, and detaching said gates.

9. The method which comprises cutting figure elements in the same relationship in a plurality of pieces of sheet material, adhesively securing said sheets together in face to 80 face relation with the edges of the corresponding figure elements in the several sheets in registry, permitting the adhesive to dry, removing the waste portions from between said figure elements with the exception of gate portions joining the several elements to maintain them in the relative positions in which they were cut in the individual sheets, dipping said elements in coloring coating material to coat both faces and exposed edges while attached to said gates, color printing said elements while attached to said gates, and detaching said gates.

10. The method which comprises cutting in each of a plurality of sheets of material and in the same relationship, figure elements joined by gate portions of waste material from which said elements are but partially severed, adhesively securing said sheets in face to face relationship with their figure elements and gate portions in registry, permitting the adhesive to harden, removing the waste material about said figure elements with the exception of said gates to form laminated figure elements connected by laminated gate portions and with the major portions of the edges of said elements exposed, performing further manufacturing operations while said laminated figure elements are so connected, and then detaching the gate portions therefrom along the lines of partial severance.

11. The method of forming wheeled toys which comprises cutting figure elements for said toys in sheet material, with cuts defining openings for axles, securing a plurality of said figures in superposed relation with said opening-definin cuts in registry, and with the waste materials within said cuts in posit1on, and ejecting the waste defined by said cuts and inserting an axle for wheels through each of the resulting openings.

12. The method of forming wheeled toys which comprises cutting figure elements for said toys in sheet material, with cuts definmg openings for axles, securing a plurality of sa1d fi ures in superposed relation with said opening-defining cuts in registry, and with the waste material within said cuts in position, applying coating material to said figures, and ejecting the waste defined by said cuts and inserting an axle for wheels through each of the resulting openings.

13. .The method of forming wheeled toys which comprises cutting figure elements for said toys in sheet material and with cuts definin openings for axles, securing a plurality 0 said figures in superposed relation with said opening-defining cuts in registry, and with the waste material within said cuts in position, and so maintaining said waste material until it is desired to apply wheels and axles to said laminated figures, and then ejecting said waste material and inserting axles through each of the resulting openings.

14. The method of forming axle-receiving elements of wheeled articles which comprises cutting similar figure elements in a plurality of sheets of material with cuts defining an opening for an axle, securing said elements in superposed relation with said opening-defining cuts in registry, removing the waste within said cuts and inserting within and securing in the openings so formed a tubular axle-receiving member.

15. The method of forming axle-receiving elements of wheeled articles from fibrous sheet material which comprises cutting similar figure elements in a plurality of sheets of material with cuts defining an opening for an axle, securing said elements in superposed relation with said opening-defining cuts in registry, removing the waste within said cuts, and inserting within the openings so formed a tubular axle-receiving member.

16. A step product which comprises a plurality of adhesively secured superposed layers of cardboard, each of said layers having cut-outs connected by integral portions from which said cut-outs are partly severed, the cut-outs and integral connecting portions registering with each other in the several layers, said connecting portions acting to maintain said cut-outs in predetermined relative arrangement.

17. A step product which comprises a plurality of adhesively secured superposed layers of cardboard, each of said layers having cut-outs connected by integral portions at relatively short peripheral portions of said out-outs, the cut-outs and integral connecting portions registering with each other in the several layers, said connecting portions acting to maintain said cut-outs in predetermined relative arrangement while exposing the peripheral edges of said cut-outs except at said connecting portions.

18. A step product which comprises a plurality of adhesively secured superposed layers of cardboard having registering cuts defining registering openings in the several layers, the material within the cuts being present in the several layers in substantially its original position.

In testimony whereof I have afiixed my signature.

HARRY PALAIS. 

